Case Study: Global Automotive Manufacturer achieves 82% increase in powertrain assembly flexibility with eFlex Systems' eFlex Assembly

Market Change Results in Lost Sales Due to “Inflexible” Fixed Tooling Assembly Systems

Global Automotive Manufacturer was caught off guard by a sudden market shift (a spike in fuel prices) that dramatically increased demand for 4‑cylinder engines and left their fixed‑tooling 6‑cylinder lines idle, causing lost sales. To address the inflexibility of their assembly systems they turned to eFlex Systems and its eFlex Assembly solution to quickly reconfigure and standardize global powertrain operations.

eFlex Systems implemented the eFlex Assembly architecture — a plug‑and‑play flexible assembly solution that lets the customer deploy process flows without recoding PLCs or taking systems down. The change delivered measurable impact: an 82% increase in powertrain assembly flexibility, 22% higher line throughput, 10% labor reduction, more than 25% faster build/deployment of new lines, 35% cost savings on new assembly lines, reduced reliance on outside resources, and lower risk of line stoppages.